Lean Product Development Process with Design Verification Stages in the Value Stream of Automotive Industry

In the automotive industry, lean projects and innovation creation come to life by being updated under the control of systematic interdisciplinary process flows. The lean product development process that changes the shell, defined under the light of the variables created by the competitive conditions, is today measured by the value flow efficiency and the global market spread of the final product. Consequently, the lean product development approach, which aims to identify and purify all the wastes that do none value or create value to the system or cause burdens in the new product development process, is shaped by step-by-step approvals in the flow. In the main automotive industry company practices within the scope of the research (3 national, 3 international), the beginning of the concept of lean in design is to define and optimize the steps in the product development process under the value stream map. Therefore, the product function for which the customer has paid for, the function of the new product or the physical structure used to meet the needs in question, the comfort, life, experience, innovations of the scope that constitute the new product concept are planned and verified and implemented in the simplified automotive design stages at the beginning of the lean product development process. In this research, initial automotive design objectives and stages are at the focal point of the innovation and added value creation brought by the concept of “lean” approach. The research is modelled on the determination of steps that do not create added value together with the points where the flow circuits’ or stems, the process is devalued, the interdisciplinary holistic studies intensify, the information and delay begin and end in the sequential and simultaneous design validation step transition stages, which are examined under the lean approach. As a visual and virtual tool that enables the elaboration of nominal values such as the total duration of the design verification stages and the influence of interdisciplinary stakeholders or the test level of the product design with the new product added, it reveals the value flow or losses. Hence research;from innovation creation and new product design steps, which constitute the initial stages of the lean product development process, to design verification analysis, the efficiency of the automotive company processes within the scope of the research has been measured by comparing using lean automotive design techniques, methods and concepts.

Autonomous Vehicle Design in Lean Product Development Processes for Value Stream Map

The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the main purpose of the research is to comparatively evaluate the impact of autonomous vehicle technologies, which are newly included in the automotive manufacturing industry under sustainable competition, on lean product development processes, value acquisition and preservation, in different organizational structures in the approach. Although mergers or brand acquisitions in the global automotive industry create joint R & D (Research Development) or joint new P & D (Product Development) process structures for the development of autonomous vehicle technologies, heavy competition continues in the market. These new processes create different needs for the merger and partnership of the renewed traffic infrastructures under national and international regulations, and for the implementation of the new autonomous life model. Firm and brand marriages, mergers or acquisitions in today’s automotive industry have ensured the high diffusion of lean product development processes under the stream of value creation or preservation carried out specific to the company under competition. Brand mergers in automotive industry companies struggling to survive under high competition create new work disciplines, professions, and engineering flow steps in lean product development processes. However, lean product development processes driven by technological innovation under simplification have resulted in the integration of parts and systems within the autonomous vehicle design structure, as well as creating new interdisciplinary value streams or different stakeholders. Therefore, the research revealed the significant effects of lean product development processes on the value stream in the automotive industry, on the mixed and lean product development process structure formed by new or existing vehicle systems (conventional vehicle) under the penetration of each existing and new discipline. This research compares the efficient operation steps of the process stakeholders in the autonomous vehicle design parts or systems containing innovation and new technology together with the value stream in the lean product development process, and the new process stakeholder’s business-oriented global and local automotive industry companies. New autonomous vehicle technologies, together with their unique software, hardware and development analysis, have been involved in the lean product development process with their interdisciplinary studies or expertise. Therefore, the study firstly focused on the technologies in environmental use together with the new basic features of autonomous vehicles, and then examined in depth the new or existing disciplines and interdisciplinary basic structure that these innovations affect under the value stream in the lean product development process. In addition, micro-level results and recommendations were shared, shedding light on how autonomous vehicle levels will create changes in the new product development process.

Evaluation of Lean Product Development Stages of Autonomous Vehicle Technologies with AHP Method

The potential innovation and emerging workforce created by autonomous vehicle technologies, which have just entered the lean product development disciplines, play an important role in the development or change of the automotive manufacturing industry. Therefore, the intensity of work and the innovation practices brought by the technologies in question at each step of very different and interdisciplinary studies deeply affect the new and lean product development steps. Comparatively measuring the operating weight of new autonomous vehicle technologies in different company structures in these lean product development steps has important consequences for the development and change of the automotive industry under heavy global competition. On the other hand, it is difficult to measure the innovation input or the use of new autonomous technology under the AHP mathematical model of each part that constitutes the whole of the lean product development process, but it also creates the future predictions of the sector. The Analytical Hierarchy Process (AHP), which is one of the multi-purpose decision-making methods, was used to determine the most intense value creation, the design and development phase where there is innovation input, or the lean product development discipline throughout the whole process. The AHP method was preferred for the comparative analysis and synthesis of different applications or similar approaches in the automotive manufacturing industry companies (global and local) and lean product development processes in the field study of the research, under qualitative data. Under the AHP mathematical model created in the research, it was aimed to measure interdisciplinary clusters with a focus on new technology and to identify similarities or differences under alternative applications created by different company structures and to compare them systematically and evaluate them mathematically. In the study, the AHP mathematical model was used to compare lean product development processes and the use of new autonomous vehicle technologies, and the Expert Choice program was preferred in the application of the method.

Exploiting Virtual Elasticity of Production Systems for Respecting OTD-Part 1: Post-Optimality Conditions for Ergodic Order Arrivals in Fixed Capacity Regimes

Respecting the on-time-delivery (OTD) for manufacturing orders is mandatory. This depends, however, on the probability distribution of incoming order rate. The case of non-equal distribution, such as aggregated arrivals, may compromise the observance of on-time supplies for some orders. The purpose of this paper is to evaluate the conditions of post-optimality for stochastic order rate governed production systems in order to observe OTD. Instead of a heuristic or a simulative exploration, a Cartesian-based approach is applied to developing the necessary and sufficient mathematical condition to solve the problem statement. The research result demonstrates that increasing speed of throughput reveals a latent capacity, which allows arrival orders above capacity limits to be backlog-buffered and rescheduled for OTD, exploiting the virtual manufacturing elasticity inherent to all production systems to increase OTD reliability of non JIT-based production systems.

卡片导航平衡控制系统性能仿真研究

为了减少装配作业车间内因物料齐套产生的等待浪费,使具有装配约束的关联零件加工进度得到有效协同,设计一类卡片导航平衡控制系统(control of balance by card-based navigation,COBACABANA)。其基于两类卡片循环回路实现任务投放与作业分派的可视化进度协同控制逻辑。本文详细介绍系统的运行机制和系统控制参量,通过构建一般化的装配作业车间仿真模型,探讨在不同装配关联度下各控制参量的性能变化。实验结果表明,COBACABANA系统性能良好,并且选择合适的控制参量就能够有效提升关联零件的进度协同性。

数字化精益生产体系构建研究——基于某装配车间实例分析

从精益化、数字化到智能化,企业的转型和升级是企业维持长远、可持续发展的必要手段。在近10年中,国际产业格局重大调整,是中国制造业转型和革新的重要时机和窗口。目前,国内仍有许多企业停留在工业3.0或工业2.0向工业3.0的过渡状态,从上到下的发展步调不平衡、不一致,处于单项覆盖而难以系统集成的阶段,没有形成一个统一体系,导致存在信息传递不及时和数据分析不全面的问题。以某动车装配车间的建设为例,从产线规划、产线构建、运行管理和优化改进等4个方面,建立数字化车间的体系结构,实现从工位到产线再到车间的精益化和数字化融合,进一步推进企业从精益化到数字化再到智能化的转型。

智能制造背景下精益生产制造执行系统的应用

[目的]在智能制造中,制造执行系统(MES)面向生产线执行层,是信息化管理系统的核心组成部分。随着精益生产模式在轨道交通车辆制造业的快速推广,在提升产能的同时,也暴露出因制造资源管控松散、生产数据收集不便捷等因素产生的信息孤岛和信息断层所带来的问题,因此需对MES的应用情况进行分析。[方法]结合轨道交通车辆产品工位制节拍化生产组织模式,以及多品种、小批量离散制造等特征,基于结构化工艺设计和移动互联技术,搭建了基于精益生产工位制的MES。[结果及结论]通过构建生产要素三维立体关系,实现了结构化工艺设计输出驱动现场执行;以移动终端作业为引导,实现了生产透明化管理;对MES进行纵向横向拓展,通过对底层设备数据进行管理,实现了制造数据的互联互通。基于精益生产工位制MES的建设,实现了生产工艺可控、生产资源网格化、生产过程透明化的制造全过程动态管控。

Approaching lean product development using system dynamics:investigating front-load effects

Competing with successful products has become perplexing with several uncertainties and transmutes from time to time as customers' expectations are dynamic.That is why manufacturing firms exhaustively strive to look for a better competitive frontier using wellestablished and innovative product development(PD)processes.In this paper,we would like to answer three research questions:(i)What would be the effects of frontloading in PD?(ii)Can we improve our PD process endlessly?(iii)When is the critical time that the firm should take remedial action for improvements?As a contribution to the vast numbers of improvement methods in new product development(NPD),this paper investigates the effects of front-loading using set-based concurrent engineering(SBCE)on cost and lead time.Models are developed and treated using a system dynamics(SD)approach.We assign a hypothetical upfront investment for SBCE and compare its effects on total cost and lead time of the development process.From the research,it is found that the total cost of PD is reduced almost by half-although the front loading is higher in order to encompass multiple design alternatives.The total product lead time is reduced by almost 20%.The model reveals the critical time for improvement of the PD process.We use SD tool(e.g.,STELLA)for simulation and visualization of the complex PD model,using SBCE as one of several strategies to frontload activities in the NPD process.

卷烟工业企业精益生产管理体系构建研究

构建精益生产管理体系对于提升卷烟工业企业生产效能具有重要的意义。本文在概述精益生产的源起、概念与特征的基础上,总结归纳了当前卷烟工业企业精益生产管理中存在的主要问题,并以问题为导向,提出了卷烟工业企业精益生产管理体系构建的主要内容以及相对应的3项保障措施,以期能够为广大卷烟工业企业所参考。

非标产品制造过程中的精益质量管理

如今质量竞争已经成为国际贸易竞争的关键。以重钢机械的国际化历程为背景,以质量管理的理念和模式为线索,从产品定位、质量管理的作用、质量体系构建、质量管理向精益质量管理的转型方面介绍天津重钢机械装备股份有限公司的质量管理模式,旨在启发中小型企业在发展过程中对质量管理和占领国际市场的思考,为中小型企业改进管理模式提供借鉴和参考。

管理4.0——试论第四次生产管理体系变革

自从亚当·斯密提出劳动分工理论后,生产管理体系伴随着工业革命先后经历三次重大的体系变革,即古典管理体系、科学管理体系和精益管理体系。随着第四次工业革命的到来,新一轮生产管理体系变革可能即将发生。客户需求特性正在发生深刻的变化,“小批量多品种”将逐渐转变为“单件无限品种”。一种应对这种需求特性变化的“量子化生产方式”可能应运而生。相应的生产管理体系也会从精益管理向互联管理转变。管理4.0时代或许即将到来。

电力系统数字化台区精益化管控

随着现代化改革时期的到来,我国结合“30、60减碳时间表”进一步提出了构建清洁低碳和安全高效能源体系的战略,要求在电力泛在物联网条件下,一方面持续推进新型电力系统高质量发展,另一方面借助技术赋能路径全面提升新能源消纳能力,有效实现负荷可调可控等目标。文章以此为背景,概述了精益化管理,并在剖析电力系统实施数字化台区精益化管控意义的基础上,对其实施策略进行了具体探讨。

基于精益生产理念的产教融合实践培训

本论文以某汽车企业为案例研究对象,旨在探讨在汽车制造业中实施产教融合实践培训的方法和效果。通过研究精益生产理念的概念和原则,以及产教融合实践培训的核心目的,提出了基于GMS体系的培训方法。通过案例研究,论文详细分析了某汽车企业的背景和业务概述,并探讨了培训内容、方法和效果评估。研究结果表明,基于精益生产理念的产教融合实践培训能够为企业培养高质量人才、降低成本,使学校教育内容贴近实际需求,促进学校的就业和教育发展,对产业兴国起到积极的推动作用。

多品种小批量精益生产方式适应性分析

精益生产方式是在丰田生产方式基础上发展起来的一种强调彻底消除浪费、减低成本和持续改善的准时化生产方式。其目的是通过流程整体优化与持续改进,均衡物流,高效利用资源,最大限度消除浪费,降低成本,缩短周期,以最少的投入向顾客提供最完美价值的目的。

精益生产系统运作优化模型及求解方法

针对传统生产方式的不足和精益生产的要求,在分析精益生产系统运作的基础上,提出将精益生产的运作优化问题抽象为具体的大系统多目标规划问题。以车间制造元素的工作量作为决策变量,以产量、质量、成本、交货期等指标为动态约束条件构建优化运作模型。在模型中引入目标函数优先级及优先权因子,以反映多个相互矛盾目标的重要程度,可以根据实际问题的动态属性确定系统的最佳运作目标需求。为解决精益生产系统运作优化的动态性、多目标、多阶段性,给出一种采用'串式调优法'求解模型的算法。将精益生产系统运作优化模型简化为产能优化、时间优化以及平衡协调等子模型,应用'串式调优法'分别对子模型求解,结合浙江省某电能表装配生产线进行情况,将优化模型和求解算法通过Witness仿真验证,仿真结果表明了模型的合理性和求解算法的准确性、高效性。

精益造船——日本造船模式研究

通过对日本造船模式的研究,提出了精益造船模式,用有造船特征的精益生产理论,详细论述了造船生产过程中的精益生产方法,介绍了一种可供我国造船企业借鉴的现代造船模式.

基于时间熵的生产系统精益管理导入效果评价

提出了生产系统时间熵的概念,对精益管理的导入如何改善生产系统中"人、机、料、法、环"五大要素继而影响生产系统时间熵进行了分析,并以科学性和实用性为原则,结合定性与定量的分析方法,构建了生产系统精益管理导入效果评价指标体系和基于时间熵的评价模型,为定量评价生产系统精益管理导入效果提供有效依据。利用所构建的指标体系和评价模型对一家胶管企业生产系统精益管理导入效果进行了量化评价,结合该企业精益管理导入实际情况,验证了所建指标体系和模型具有较好的适用性和有效性,为生产系统的精益管理导入效果评价提供了新的思路和方法.

汽车制造企业精益生产系统模型

精益生产作为一个舶来品,大多数企业还不知道如何将之与中国企业的实际结合起来。针对我国企业实施精益生产中存在的问题,在对汽车制造企业广泛调研的基础上,结合精益生产的基本原理,为我国汽车制造企业设计一个包括行为规范、领导能力、人员培训、工作小组、全员生产维护、制造工程、工位过程控制、工业物流、同步化物流、安全管理、环境管理以及质量管理等在内的由12个模块组成的精益生产系统模型。同时,通过对精益生产体系文件结构、推进模型以及评价模型的设计,从而保证该模型能够在汽车制造企业中实现程序化、分阶段的整体实施,以及对实施效果进行有效跟踪和评价。通过该模型在汽车制造企业的实际运用,证实该模型的有效性和可行性。

面向机加与装配混合生产系统的建模与仿真技术

针对传统面向机加或装配建模与仿真割裂了两者之间协作关联生产的问题,研究精益生产模式下综合机加与装配的混合生产系统建模与仿真技术。引入齐套工位的概念,建立统一的工艺描述数据结构,解决机加与装配生产衔接的关联定义问题;以车间—工位—设备的层次化结构及其关联关系为基础,构建车间层、工序/工位/齐套层和设备层,以及面向组合生产的批处理逻辑控制器,定义控制器之间的协作接口关系,建立模块化的建模元件库;采用物理模型和控制器模型分离的策略,通过实际车间布局元素与控制器之间的映射关联,实现工艺和布局数据驱动的生产系统自动建模;采用将生产系统的运行映射为控制器之间交互协作的方法,提出任务数据驱动的层次化和模块化的仿真运行控制机制,实现基于设备、队列以及生产对象仿真运行事件的统计分析,为基于仿真的优化决策提供了支持。结合某研究所的混合生产系统,通过生产任务投产时间安排的对比统计分析案例表明,该技术能够有效支持数据驱动的机加与装配混合生产系统的快速、柔性建模与仿真,为精益生产提供了决策分析手段。

精益企业理念与精益生产实现模式研究

本文通过对精益生产和企业理念特征的研究，揭示了精益生产与企业理念的内在本质联系；通过对当前生产企业所面临的内外部环境的研究，分析了精益企业理念的特征。